Cladding for a modular frame structure

ABSTRACT

A cladding of a modular frame structure, of the type used for assembling complex frames of buildings by interconnecting module frames identifying an outer wall of the building, is provided. Each module frame has a substantially parallelepiped shape and it is identified by longitudinal, vertical and transversal beams joining at respective angles. The cladding includes respective inner panels the edges thereof are wholly sustained inside said beams, including the overlapping of a pair of layers: a first bearing layer facing outwards, and a second insulating thermal layer facing inwards; outer panels in contact with the inner panels include a box-like reinforcement, which defines the inner face, having a compensation foil made of compressible material, rested on an inner panel, and an outer face having a plurality of fastening pins infixed in the wall of the reinforcement; and a flat element of outer finishing, forming an air gap.

The present invention relates to a cladding of a modular framestructure, of the type used for assembling even complex buildings. Undermodular frame a complex frame is meant, obtained by means ofinterconnecting several module frames identifying an outer wall of thebuilding, which has to be cladded, as well as a plurality ofintermediate floors and partitions which give shape and function to thebuilding.

International patent application N. WO 2004/033,809 A1 describes acladding formed by joining two panels spaced-apart by a plate with aZ-like profile, with a peripheral frame constituted by closing beams,which then are used for assembly with a supporting frame.

European patent application N. 2,213,807 A1 describes a modular wallformed by spacing elements and several overlapped panels.

European patent application N. 2,444,565 A1 describes a connectionsystem for panels arranged on a building façade, wherein the frameworkincludes a metallic rigid element which is used for connecting theplates and which gives the structure the required resistance.

Even British patent application N. 2,524,025 describes an assemblystructure for panels, comprising a framework constituted by elementsfixed therebetween, to provide passage channels for electrical services.

International patent application N. WO 2010/139,681 A describes acladding system with a supporting element fastened to a bearing wallsustaining an outer panel so as to determine an air gap, with additionalintermediate panels arranged to form additional air gaps.

U.S. Pat. No. 6,134,860 A relates to a frame for prefabricatedstructures constituted by coupled walls implementing a support forsurface boardings.

U.S. Pat. No. 6,256,960 B1 describes a prefabricated building withframework-like peripheral elements which are used to position the outerwalls.

US patent N. 2010/0095621 A describes an insulating panel provided withfixed joints for assembling additional panels.

US patent application N. 2012/0247043 describes a building modularsystem wherein frame peripheral elements define passages in which panelsare inserted constituted by an outer foil, an inner foil, and aninsulating intermediate element.

British application N. GB 2,412,385 A describes a cladding according tothe preamble of the enclosed claim 1, however without intermediatecladdings between different module frames.

Even International patent application N. WO 98/56,999 A1 and Frenchpatent application N. FR 2,951,213 A1 describe details inherent to thecladdings of module frames.

Therefore, the state of art offers very diversified solutions, but theyhardly adapt to a modular frame formed by beams and by knots of metallicnature, which can be used in climatic areas very different therebetweenand which however has to guarantee an insulation adequate to thereference climatic area, without thermal bridges causing not correctlyinsulated areas, with a consequent energy loss.

The technical problem underlying the present invention is to provide acladding of a modular frame structure allowing to obviate the drawbackmentioned with reference to the known art.

Such problem is solved by a cladding of a modular frame structure asdefined in the annexed claim 1.

The main advantage of the cladding according to the present inventionlies in allowing, the assembly procedure being equal, a considerablefreedom in selecting thicknesses and materials which adapt to a framewith beams and metallic joints, by obtaining an overall homogeneous andoptimum insulation.

The present invention will be described hereinafter according to apreferred embodiment thereof, provided by way of example and not withlimiting purposes by referring to the enclosed drawings wherein:

FIG. 1 shows an axonometric view of a complex frame resulting fromassembling several module frames of the structure, which is suitable toreceive a cladding according to the present invention, wherein thementioned dimensions represent purely indicative and not limitingvalues;

FIG. 2 shows a detail of a module frame of FIG. 1, with an exploded viewillustrating the scheme for assembling a cladding according to thepresent invention;

FIG. 3 shows a vertical section of a complex building illustrating boththe complex frame of FIG. 1 and the cladding of the present invention;

FIG. 4 shows a first enlarged detail of the cladding of FIG. 3 in crosssection;

FIG. 5 shows a horizontal and partial section of the cladding of FIG. 3;

FIG. 6 shows a front view of the cladding of FIG. 3;

FIG. 7 shows a second enlarged detail of the cladding of FIG. 3 in crosssection; and

FIG. 8 shows a third enlarged detail of the cladding of FIG. 3 inhorizontal section.

By referring to FIG. 1, a complex frame of a modular building structureis designated with 1; it is constituted by a certain number of moduleframes which has a substantially parallelepiped-like shape and areidentified by the longitudinal beams 2, by the vertical beams 3 and bythe transversal beams 4.

Under parallelepiped, herein a straight parallelepiped with rectangularfaces is meant. Each module frame has sizes allowing it to fall withinthe shape of a container which can be transported by ordinary route, incase loaded on the platform of an articulated vehicle, without requiringa special transportation to move it from the assembly site to theproduction site. A building module then will correspond to each moduleframe, the building module comprising the related claddings which willbe described hereinafter, and which can be assembled at works, beforethe transportation to the laying site.

Each module frame has then angles wherein the longitudinal, vertical andtransversal beams 2, 3, 4 join. At such angles, the complex frame 1comprises a plurality of connecting knots 5 joining module framesadjacent laterally on the same horizontal or vertical plane, on thelower side or upper side on staggered planes, or providing for theconnection of the module frames to a suitably arranged flat basement 80,or to a not represented roof structure.

In case of adjacent module frames, they could be faced at alongitudinal, vertical, upper or lower wall; otherwise, in case offrames on staggered planes, they will have in common an edge with twobeams of the same type faced one onto the other one.

Therefore, the shapes of each knot 5 change according to the knotposition, in particular each knot 5 should be capable of providing forthe mutual connection of a number of module frame varying from one toeight and thereof with basement 80.

Generally, each knot 5 has a box-like structure with a cubic and hollowparallelepiped-like shaped inner core 6, formed by six walls faced twoby two, each wall with a circular opening so that they form respectivechannels opened according to orthogonal axes X, Y and Z. Such channelsare opened, and the core inside provides a space for passing through achannel or from a channel to the other one.

The core could be made of a suitable material, for example steel,preferably in one single piece and with adequate thicknesses, so as tohave the resistance required for any design stress.

Furthermore, at each opening, the core 6 comprises a correspondingsupporting plate 7, for a total of six supporting plates, parallel ororthogonal therebetween two by two; in particular, the plates 7 ofopenings one in front of the other one are parallel therebetween, andthe plates 7 of openings on adjacent plates are orthogonal therebetween(FIG. 2).

Even the supporting plates could be made of suitable material, in casein one single piece with the core 6, or by means of welding of pieces.

Each supporting plate 7, if it extends beyond the plane defined by anadjacent plate 7, defines therewith an angular or side rest for a moduleframe angle.

By referring to FIG. 2, on an angle of the core 6 the plates 7 extendbeyond the two adjacent plates and vice versa, by determining an angularrest formed by three supporting plates 7 which form an angular spacewith three resting walls.

Otherwise, at an edge of the core 6, two supporting plates 7 can extendone beyond the other one and vice versa, by forming a side rest formedby two L-like positioned plate ends.

In case a supporting plate 7 is not crossed by any of the adjacentplates, it forms a resting plane which can be connected to a basement ora roof (FIG. 2).

The shape of the knots 5 then allows not only to connect adjacent moduleframes, but to space apart them one from the other one. This determinestwo substantially combined effects:

-   -   1. the overall sizes of the complex frame obtained by assembling        module frames will be larger than the sum of the sizes of the        single module frames; and    -   2. the distance between each module frame could allow, together        with the presence of the above-mentioned channels in each knot        5, to arrange easily through plants of electric, water nature        (mains water, white water, waste water, heating, refrigeration),        air conditioning plants, service tubes, alarm plants and so on.

The first one of said effects allows to make each pre-assembled modulecapable of being transported in a simple way, as a usual container, andthen to obtain a building the overall sizes thereof would not beotherwise compatible with normal transportation systems.

To this regard, the previously described angular rests will be useful toreceive the angles of each module frame. Each angle will include abox-like connecting element 8, formed by two or three walls connectedtherebetween, which will be in contact with the respective rest.

Advantageously, the frame beams have a L-like section with the innerangle facing towards the inner space of the module frame, to provide asupport to the edges of the inner panels 9 which will be describedhereinafter with greater detail.

The L-like beams, as well as the connecting elements 8, could be made ofsuitable material, for example a folded or forged steel plate, orobtained by welding.

Each module, although formed by a frame which repeats module by module,could assume very different shapes, but it will include, at the wallsforming the outer surface of a complex building, outer paddings whichcould be adapted to the climatic area of interest.

At the outer surface of the complex frame 1, the rests arranged by theknots 5 could receive respective stopper-like elements 10, for closingthe opening faced outwards, and framework elements 11 extending from aknot to the other one and which will be used to support a cladding panel20. They will be described hereinafter with greater details.

In this way, on the same outer wall, each so-obtained framework wouldprovide a different cladding, so as to obtain different compositions.

It is to be noted that the above-mentioned stopper-like elements and theframework elements have the task, together with the panels 20, to closethe outer surfaces of the building, but even to implement a sealpreventing the air from entering the intermediate spaces between themodule frames 10, acting as thermal and acoustic insulation and even forfireproofing purposes.

Such seal can be implemented thanks to self-expanding belts and gaskets,arranged on the edges of the stopper-like elements and of the frameworkelements.

The above-described structure obtained by assembling the knots 5 withthe module frames further allows to obtain an adequate resistance toearthquake motions according to the existing rules.

Each module frame 10 could include elements for reinforcing thestructure thereof. In particular, the section of the beams 2, 3, 4 couldbe of box-like type; the beams could be connected by vertical strutsarranged on the vertical faces, or angular brace assemblies oradditional diagonal beams, or even transversal currents on any face.

By referring to FIGS. 3 to 8, the above-mentioned claddings will be nowdescribed in greater detail.

In particular, the outer panel 20 comprises a box-like reinforcement 21made of wood or steel; inside, the reinforcement 21 comprises angularelements 22 for assembling the walls constituting the reinforcement,which thus results to be closed. Inside, the reinforcement 21 has afiller 23 which could be selected in relation to the use climatic area.

For example, such filler 23 could comprise panels made of wood fibrewith variable density, selected based upon the climatic area.

The filler will be included in a casing made of cloth or paper toguarantee the air seal and the thermohygrometric equilibrium of thefiller 23.

The reinforcement 21 defines an outer face and an inner face of theouter panel 20. On the inner face, the panel comprises a compensationfoil 24 made of compressible material, which is suitable to be rested onan inner panel 9.

The compressibility of the foil 24 guarantees a perfect adhesion to theinner panel and the assembly clearance compensation. The material of thecompensation foil 24 can be cork or other material suitable tocompensate a possible clearance and the thickness of the plate whichconstitutes the beam, for example a thermoplastic material such asneoprene.

On the outer face, the outer panel 20 comprises a plurality of fasteningpins 25 infixed in the wall of the reinforcement 21 through the angularelements 22, which are stiff and made of metallic material, thus byoffering the required structural support.

A flat element of outer finishing 26 can be assembled to the fasteningpins 21 existing at each angle of the outer panel 20, which flat elementforms an empty air gap 27 between it and outer face of the outer panel20.

For the above-mentioned assembly, the fastening pin 25 is equipped withL-like connecting elements 28, equipped with suitable slotted holes forengaging a bolting 29 made of steel.

The flat element 26 can be constituted by a panel of any nature: forexample a panel made of treated wood, steel, aluminium, a stratifiedlayer made of glass or other transparent or semi-transparent material, asheet of compressed concrete, a plate made of natural or artificialstone (marble etc.), a photovoltaic module.

By referring to FIG. 6, the outer panel 20 can be constituted by aplurality of panel-like elements 40 arranged edge against edge to form amore extended plane, with an overall size to constitute a cladding for awhole wall of module frame (FIG. 6); this assembling can be implementedby fixing therebetween the end angular elements 22 of each panel-likeelement 30 through the respective reinforcement 21.

The inner panel 9 instead comprises the overlapping of a pair of layers:a first bearing layer 91, which for example can be made of wood, inparticular of multi-layered wood, and which is facing outwards; and asecond insulating thermal layer 92, for example a layer made of avegetable fibre such as linen, which is facing inwards.

On the inner face of the inner panel 9, then on the second layer 92,there is a barrier 93 for the air seal and to keep a thermohygrometricequilibrium of conventional type, and in case a layer of plaster fibre94.

The same type of inner panel 9 can be used for the ceiling of each innerenvironment (FIG. 3), whereas the floors, designated with 30, willcomprise, too, a first bearing layer 91, still made of multi-layeredwood, facing downwards, as well as a plurality of insulating layers 95which can include foam material of vitreous type (ex. expanded perlite),vegetable fibres (fibres made of wood, cellulose, an air gap 99 betweenthe bearing layer and the insulating layers, and, of course, a coating97 for floors on the surface exposed to trampling.

In the insulating layers 95 and in the air gap 99 ducts or pipes relatedto plants integrated in the floor can be provided, for example ducts forthe hot water of a floor heating, ducts for electrical cables, alarmsystems and so on.

By referring to the complex frame 1 resulting from assembling the moduleframes, the horizontal edges, both those at the basement and the roof,and those corresponding to the inner floors, the cladding comprisesfirst box-like elements arranged at the conjunction of the inner panels9 and of the floors 30.

The first box-like elements 31 comprise a box made of steel 32 with afiller 36 which comprises an insulating material, for example a foammaterial such as expanded perlite (FIG. 8).

Even the vertical edges of the complex frame comprise a second box-likeelement 33 (FIG. 8) analogous to the previous one, arranged at therespective inner panels 9.

At last, at the vertical beams 3 and the horizontal beams 4 arranged onthe exposed faces of the complex frame 1, the cladding comprises thirdbox-like elements 34 which, differently from the previous ones, comprisea box made of wood 35 and a filler analogous to the previous one (FIGS.7 and 8).

The above-mentioned box-like elements can be opened, to allow screwingthe beams of the module frame to the knot, once the box is empty. Oncecompleted this assembling phase, the box is closed and filled up with afiller 36, which is even heat insulating and fireproofing agent.

It is to be noted that pins 25, analogous to those already described,can be fastened to the box made of wood 35, which pins support a beamcover 37 acting as joint between the flat elements of outer finishing26, with snap insulating connections 38 arranged at the respective edges(FIG. 7).

The third box-like elements 34 then constitute the stoppers 10, forclosing the openings of the joints 5 faced outwards, and the frameworkelements 11 of FIG. 2.

With the above-described arrangement, it is possible implementing anouter cladding of a complex frame, thus by forming a complex building,almost suitable to any climatic area: it is sufficient selectingsuitable insulating materials and suitable thicknesses withoutintervening on the frame.

Furthermore, whatever the thicknesses and the materials selected toadequate the cladding to the climatic area are, the inner sizes of themodule frame remain the same, so that it is possible planning differenttypes of module frame, equipped with inner panels and floors, withoutthe design being influenced in any way by the target climatic area.

In the same way, the widest selection freedom remains, as far as theouter boarding is concerned, which could or could not participate in theoverall thermal insulation, or otherwise it could be destined todecorations or finishings of any type or to the implementation ofphotovoltaic panels.

The above-described components will be treated in order to havefireproofing, anti-intumescent features, and to be protected fromcorrosion.

To the above-described cladding of a modular frame structure a personskilled in the art, in order to satisfy additional and contingent needs,could introduce several additional modifications and variants, allhowever comprised within the protection scope of the present invention,as defined by the enclosed claims.

1. A cladding of a modular frame structure, of the type used forassembling complex frames (1) of buildings by interconnecting severalparallelepiped-shaped module frames identifying outer walls andintermediate floors and which are formed by longitudinal (2), vertical(3) and transversal beams (4) joining at respective angles at arespective connecting knot (5) joining module frames adjacent at saidangles, or providing for a connection of the module frames to a flatbasement or to a roof structure, wherein the cladding comprises:respective inner panels (9, 30), edges thereof are sustained inside byedges of the beams (2, 3, 4), comprising a first bearing layer (91)facing outwards, and a second insulating thermal layer (92) facinginwards; outer panels (20), arranged in contact with said inner panels(9) outside the respective module frame, comprising a box-likereinforcement (21), with a filler (23) selected in relation to the useclimatic area, having a compensation foil (24) made of compressiblematerial, rested on an inner panel (9), and a plurality of fasteningpins (25) infixed in the wall of the reinforcement (21); a flat elementof outer finishing (26), forming an empty air gap (27) between it and anouter face of the outer panel (20) sustained by said fastening pins(25), wherein each connecting knot (5) has a box-like structure with acubic and hollow parallelepiped-like shaped inner core (6), formed bysix walls faced two by two, each wall with a circular opening therebyforming respective channels opened according to orthogonal axes, andcomprising supporting plates parallel or orthogonal therebetween two bytwo, by defining side and angular rests, at an outer surface of thecomplex frame (1) the connecting knots (5), on said side and angularrests, have respective stopper-like elements (10), for closing theopening faced outwards, and framework elements (11) extending from aknot to the another knot and which is configured to support a claddingpanel (20).
 2. The cladding of a modular frame structure according toclaim 1, wherein said frame beams (2, 3, 4) have an L-shaped sectionwith an inner angle thereof facing towards an inner space of the moduleframe, and wherein the edges of the inner panels (9) are sustainedinside said L-shaped sections.
 3. The cladding of a modular framestructure according to claim 1, wherein the box-like reinforcement (21)has walls made of wood connected by angular metallic elements (22) towhich said fastening pins (25) are connected.
 4. The cladding of amodular frame structure according to claim 1, wherein said filler (23)comprises panels made of wood fiber with variable density, selectedbased upon the climatic area.
 5. The cladding of a modular framestructure according to claim 1, wherein said compensation foil (24) ismade of cork.
 6. The cladding of a modular frame structure according toclaim 1, wherein said flat element (27) is selected from the groupconsisting of: a panel made of wood, steel or aluminum, a stratifiedlayer made of glass or other transparent or semi-transparent material, asheet of compressed concrete, a plate made of natural or artificialstone, and a photovoltaic module.
 7. The cladding of a modular framestructure according to claim 1, wherein said outer panel (20) isconstituted by a plurality of panel-like elements (30) arranged edgeagainst edge to form a more extended plane.
 8. The cladding of a modularframe structure according to claim 1, wherein said first bearing layer(91) is made of wood, or plywood, and the second insulating thermallayer (92) is made of a vegetable fiber.
 9. The cladding of a modularframe structure according to claim 1, wherein on an inner face of theinner panel (9) there is a barrier (93) for an air seal and to keep athermohygrometric equilibrium, and optionally a layer of plaster fiber(94).
 10. The cladding of a modular frame structure according to claim1, wherein said first bearing layer (91) is made of wood, or plywood,and the second insulating thermal layer comprises a plurality ofinsulating layers (95) made of foamed material of vitreous type andvegetable, fibers with an air gap (99) between the bearing layer and theinsulating layers, said inner panel (9) constituting a floor (30). 11.The cladding of a modular frame structure according to claim 1, whereinat horizontal and vertical edges, both at the basement, the roof andbetween vertical walls, and those corresponding to the inner floors,comprise first box-like elements (31) arranged at a junction of theinner panels (9, 30).
 12. The cladding of a modular frame structureaccording to claim 11, wherein the box-like elements (31) comprise a boxmade of steel (32) with a filler (36) which comprises an insulatingmaterial.
 13. The cladding of a modular frame structure according toclaim 1, wherein at the vertical beams (3) and the horizontal beams (4)arranged on outer faces of the building, comprises box-like elements(34) with a box made of wood (35) and a filler which comprises aninsulating material.
 14. The cladding of a modular frame structureaccording to claim 13, wherein said box-like elements (34), comprise abeam cover (37) acting as joint between the flat elements of outerfinishing (26), with snap insulating connections (38) arranged at therespective edges.